Method of decorating surface coverings



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Oct. 18, 1949.

METHOD OF DECORATING SURFAACE COVERINGS Filed Nov. 21, 1945 Oct. 18, 1949. F. J. sHwARz METHOD 0F DECORATING SURFACE COVERINGIS 3 Sheets-Sheet Filed Nov.. 2l, 1945 IN VEN TOR.

Oct. 18,1949. F. J. scHwARz 2,485,541

METHOD OF DECORATING SURFACE COVERINGS l Filed Nov. 21, 1.945 s sheets-sheet. s

INVENTOR.

Patented Oct. 18, 1949 METHOD OF DECORATING SURFACE COVERINGS Frank J. Schwarz, Lancaster, Pa., assignor to Armstrong Cork Company, Lancaster, Pa., a corporation of Pennsylvania Application November 2l, 1945, Serial No. 630,046

9 claims. (o1. lliv- 11) This invention relates to a method of printing oor and wall coverings in representation of tile with mortar joints separating the tile elements. It is desirable in printed wall coverings particularly to have the mortar representing lines disposed in a plane below the plane of the tile elements. It is also desirable to have the edges of the tile elements gradually merge into the mortar representing portion to enhance the effect of the covering, since clay tile used in wall coverings generaly has beveled or cushioned edges so called.

I-Ieretofore this effect has been obtained by printing or coating the base material with one or more layers of paint in a color representing the mortar joints. This coated material was then stoved to mature the paint and the covering was then fed to a printing machine which applied the tile representing elements to the face of the material in open pattern, leaving the base coating material to show through in the mortar joint representing areas. By this method the areas in representation of tile were disposed above the interliner representing portion, but this process is rather expensive and is also objectionable because it requires the stoving of the material rst, after the application of the base coating or coatings, and again after the application of the tile representing paint.

This prior process has also been found objectionable because of the waste of materials required in its practice. The application of an all-over coating of paint to the surface of the foundation is expensive and -since the major portion of the area of the covering is in the tile representing portions rather than the mortar joint representing portions, all of the paint which is applied to areas other than the mortar joint representing portions is in effect wasted since it lies below the tile representing portions and is not exposed to view, and, insofar as wear is concerned, the covering is replaced when the tile representing portions have been worn away.

It is an object of my invention to provide a process for the manufacture of floor or wall coverings in simulation of tile with depressed mortar joints wherein the covering is completed in one printing operation and requires but a single stoving.

Another object of my invention is to provide a method whereby the tile and mortar joint representing areas are applied s ide-by-side instead of having the tile areas disposed over themortar joint paint layer as in the prior art practice.

Broadly stated, my process consists in rst printing upon a suitable foundation a colored paint or the like in the areas of the backing which will represent the mortar joints in the nal product. As a second step, the paint so applied and while still wet is leveled and reduced in thickness; this being accomplished preferably by use of a doctor blade which is brought into engagement with the paint and drawn thereover, Thereafter paint in the tile representing color or colors is applied to the foundation in the areas not covered by the mortar joint representing paint; such tile representing colors being applied so as'to cover any irregular edges which may result from the smoothing operation upon the mortar joint paint.

In order that my invention may be more readily understood, I shall ldescribe the same in conjunction with the attached drawing in which:

Figure 1 is a diagrammatic view illustrating a preferred sequence of operations;

Figure 2 is a similar view which illustrates one type of apparatus effective for carrying out the process; and

Figure 3 is a diagrammatic View illustrating the surface of the covering in the progressive steps as printing is effected in accordance with the preferred practice of my process.

Before describing the preferred process, I should like to point out in connection with the various views of the drawing that in normal operation, the printing heads would be spaced apart a distance equivalent to the working width of each of the printing heads. Common practice is to have each of the heads with a working surface of 18 and the blocks are spaced apart 13". I have shown the printing blocks close together in the various Views in order to be able to show the sequence in a single series of operations on a single sheet of drawing.

Referring to the drawing, I have chosen for illustration purposes a very simple tile pattern with a single color of tile and a -second color of interliner. The foundation to which the paint is applied is indicated at 2. This preferably is an asphalt saturated felt of the type used in floor and wall covering manufacture although t may be made of linoleum or other suitable base material suitable for the particular use to which the iinal product will be put. The foundation material may be provided with one or more seal 3 coats if necessary to prevent the saturant from striking through and staining the surface of the covering.

The covering is intermittently moved through a printing machine which I have diagrammatically shown so as to bring any particular portion of the covering sequentially into the zones of operation of the various printing stations. These stations have been numbered 3 to I3 in Figure 1. At the first station, 3, the surface of the foundation 2 may be coated with a very thin layer of oil paint which may be similar in hue to that of the interliner color. This is not important and if desired, the color of this thin coat may be the same as one of the tile representing colors or may be entirely different than any of the colors appearing in the finished product. The primary purpose of this coating is to permit proper leveling of the paint which is subsequently applied to the foundation and by so doing the use of mash blocks or equivalent mechanism for leveling the applied paint may be avoided. Equivalent suitable for this purpose is shown in Prifold Patent 1,854,666, substituting a doctor blade for the brush shown in the Prifold patent.

The foundation 2 is now moved into station 4 Where a printing block I4 which has interliner printing surfaces I5 thereon is brought into engagement with the foundation and applies paint to the foundation 2 in the areas indicated at IB in Figure 3. This paint is preferably of a relatively heavy consistency and the width of the printing surfaces I5 is determined by the width desired for the interliner in the final product.

The foundation 2 is then moved another step forward into station 5 where printing block I'I provided with printing surfaces I8 applies additional paint to the interliners I6 in the areas I9 shown in Figure 3. In some instances, this Iblock may 'be dispensed with, particularly where the mortar joint representing portions are relatively narrow. In actual practice I have found that in printing with the block I4, having an interliner printing surface I5, there is a tendency for the lines which run transversely of the. goods to cut in leaving areas of the foundation either not completely covered or thinner than desired. In addition, the leveling operation which is effected subsequently has a tendency to draw the color from the transverse lines; Whereas, the longitudinal lines, extending continuously along the length of the goods, do not appear to be thinned out to an objectionable extent during the leveling operation. To overcome this problem, I prefer to make a second application of paint to the transversely directed portions I9 as indicated in Figure 3, although this may not always be necessary and, Where desirable or necessary, the printing block I'I may be provided With a printing surface so as to apply a complete color to the interliner portion.

Foundation 2 is moved to station 6 at which there is provided a leveling device which in the illustrated embodiment comprises a doctor blade which is urged into continuous engagement with the surface of the goods. The doctor blade 20 is reciprocated in a direction parallel to the length of the goods so as to be in continuous motion at a substantially uniform rate with respect to the foundation '2 although the foundation is moved intermittently thereunder in the printing operation. The knife may also be oscillated in a direction transversely of the goods. It will be noted by reference to Figure 3 that the doctor blade at station 6 serves to level and spread out the paint applied by blocks I4 and I1, there being some tendency for the colors to be smeared or spread over adjacent areas as indicated at 2l in Figure 3. It will be noted that this spreading is both longitudinally of the foundation and transversely thereof due, of course, to the fact that the blade is moved both longitudinally and transversely of the goods in the leveling operation. The step performed at station 6 is important for it serves to level the paint and reduce the thickness in the interliner areas, eliminate the necessity for applying the interliner color over the whole area of the foundation, thereby avoiding the necessity for two stoving or curing operations, and causes the paint film in the interliner areas to be disposed in a plane below the general plane of the tile representing areas as will be more fully hereinafter discussed.

The foundation 2 is 'now moved to station 'I where a printing block 22 provided with a printing surface 23 applies a color corresponding to the color of the tile representing portions in outline as indicated at 24 in Figure 3 around the periphery of each of the tile representing portions. For simplicity, I have as mentioned above shown in the drawings an apparatus for printing a single color tile. It will be obvious that the tiles may be in more than one color and in such event separate printing blocks will be used for each color and, in fact, individual tiles may be made up of more than one color to indicate shading which is characteristic of burned clay tile. I consider the outlining step desirable, for by outlining the tile representing areas in this manner, I avoid the dogtooth edges Which Would result from printing the entire tile representing areas with sawn blocks. I also find it desirable to print the outline color prior to the application of the main tile color because it is always necessary in printing with flat block type machines to use a thinner paint where the paint is applied over a previously applied color which is still wet. By applying the outline color first and applying the main block color thereover, I avoid the creation of any perceptible line of demarcation between the outlining color and the main block color which normally would result from the application of an outlining color to the block color, for with the outlining color of thinner consistency than the main block color there would be a tendency for it to be somewhat lighter in shade and noticeable in the finished product. With my process, the outline color is applied to the surface and since the block color is of such major volume as contrasted with the outline color any tendency toward noticeable difference in color is minimized.

The backing is next moved to station Il where block 25 which is provided with printing surface 26 applies outlining color to the lines which extend transversely of the goods as indicated by the portion 2l in Figure 3. This block may be said to correspond to block I'I which has printing surface portions I8 for the application of interliner color transversely of the goods. The color of the paint applied by the block 25 will, of course, be identical with that applied by the block 22. The primary purpose of the block 25 is to insure that adequate paint is applied in the areas where most of the interliner color is spread in the doctoring operation at station 6. If only a minor amount of spreading occurs at station E, it may be possible to eliminate block 25, but in my preferred practice, I use it, for it insures sharp, clean lines and positive coverage of the base Without any possibility of the interliner color showing through.

, entire tile representing color in a single operation.

In my preferred practice, I employ two separate blocks, the second block being indicated at 3| in station ID and having printing surfaces 32 which serve to completely fill the tile representing areas in the pattern by the application of paint to the areas 33 in Figure 3.

In order to apply an adequate thickness of paint for proper wear resistance and complete coverage of the surface, it may be desirable to apply a second thickness of paint in the tile representing areas. For this purpose, blocks 34 and 35 are provided at stations Il and I2. printing surfaces1 36 and 31 which correspond with the surfaces 29 and 32 of the blocks 28 and 3l respectively. Of course, if block 28 applies all of the tile representing color, then one more block may be used to apply the second thickness. I have obtained particularly good results by using four blocks for this purpose, but it will be under- `stood that one or two blocks' may be used as desired.

The use of a mash block 38 in station I3 is optional. The purpose of it is to level out the paint applied by the previous printing blocks and it tends to round-off or cushion the edges Where the tile representing areas merge into the interliners. Its use would be desirable if there is any tendency for the applied color in the tile representing areas to fail to properly level and merge nicely with the interliner at the joints. I

The blocks have have obtained good results without it, although f there are those skilled in the art who feel that the use of a mash block is indispensable in any floor or wall covering printing operation. The mash block is preferably of the so-called peg type and is well known in the art.

The foundation with the applied paint is then curedby hanging the material in a heated curing stove or oven where the paint is dried.

By my method tile patterns are provided in which the interliner is depressed or lies in a plane below the plane of the tile representing areas. The edges of the tile are rounded off or cushioned and give the product the appearance of hand laid clay tile. My process may be carried out on ordinary flat-block printing machines. A single stoving of the decorative paint is necessary and the interliner color extends substantially only in the areasv desired in the finished products rather than over the whole area of the backing as in the prior practice, and therefore, my process is most economical.

While I have disclosed the application of an oil type paint to an asphalt saturated felt base wall or floor covering, I do not wish to be limited thereto for my method is applicable with other types of bases and other types of coating materials all of which may be generically termed printing paints. Although I have shown a flat block printing machine and have made reference to sawn and peg blocks, it is obvious that my process could be carried out using rotary type printing machines and metal or other types of blocks or rollers instead of wooden sawn or peg type blocks.

While I have illustrated and described a preferred embodiment of my invention, it is understood that same is not limited4 thereto but may be otherwise embodied and practiced within the scope of the following claims.

1. Ina method of decorating flat surfaced coverings in simulation of tile with depressed mortar joints therebetween, the steps of applying paint to a flat surfaced foundation in limited areas thereof which are to represent mortar joints in the finished covering, engaging said paint while still wet with a spreading surface while effecting relative movement between the paint layer and the spreading surface ina direction parallel to the plane of the surface of the paint layer to spread the same and reduce the thickness thereof in the mortar joint representing areas, with a portion of the paint being spreadA beyond the mortar joint representing areas, and applying paint in tile representation to the foundation 'in su'cient thickness to lie above the mortar joint representing areas, said tile representing paint being applied in areas contiguous to the mortar joint representing areas and over the paint which has been spread beyond such areas in the leveling step to produce a surface decoration in which the tile representing areas lie in a plane above the plane of the mortar joint representingfareas and the mortar joint representing areas are well defined.

2. Ina method of decorating flat surfaced coverings in simulation of tile with depressed mortar joints therebetween, the steps of printing in a fluid paint upon a fiat surfaced foundation web in limited areas thereof which are to represent mortar joints in the nished covering, said areas being disposed both longitudinally and transversely of the foundation, printing additional fluid paint upon the foundation in the mortar joint representing areas which lie transversely of the length of the foundation, engaging said applied paints while still wet with a spreading surface while effecting relative movement between the paint layer and they spreading surface in a direction parallel to the plane of the surface of the paint layer to level and spread the same and reduce the thickness thereof, and thereafter printing in tile representation on the foundation in sucient thickness to lie above the mortar joint representing areas, said tile representing paint being applied in the areas between the mortar joint representing areas and over the paint which has been spread beyond such mortar joint representing areas in the leveling step with said tile representing .paint being of different color from the mortar joint representing paint, to produce asurface decoration in which the tile representing areas lie in a plane above the plane of the mortar joint representing areas and the mortar joint representing areas are well defined.

3. Inra method of decorating flat surfaced coverings in simulation of tile with depressed mortary paint layer and the spreading surface in a direction parallel to the plane of the surface of the paint layer to spread the same and reduce the thickness thereof in the mortar joint representing areas, with la portion of the paintv being spread beyond the mortar joint representing y areas, applying a narrow band of paint toV outline the tile representing areas and partially at least cover the paint which has been spread over such areas in the leveling step, andthereafter applying paint in the tile representing areas in sucient thickness to lie above the mortar joint representing areas, said tile representing paint being applied in areas contiguous to the mortar joint representing areas and over the paint which has been spread beyond such areas in the leveling step, including a portion at least of the areas previously covered in the outlining step, to produce a surface decoration in which the tile representing areas lie in a plane above the plane of the mortar joint representing areas and the mortar joint representing areas are Well dened.

4. In a method of decorating flat surfaced coverings in simulation of tile with depressed mortar joints therebetween, the steps of applying paint to a flat surfaced foundation web in an open grid work to represent mortar joints in the finished covering, engaging the paint while still wet with a flat smoothing surface to spread the paint and reduce the thickness thereof, applying a narrow outlining band of paint to the tile representing areas of the foundation contiguous to the mortar joint representing areas and covering the major portion at least of the paint spread into such contiguous areas in the leveling step, applying additional outlining paint along those portions of the outline which extend transversely of the web, and thereafter applying paint of the same color as the outlining color to the tile representing areas, including a portion at least of the areas covered by the outlining paint, to produce a surface decoration in which the tile representing areas lie in a plane above the plane of the mortar joint representing areas.

5. In a method of decorating fiat surfaced coverings in simulation of tile with depressed mortar jbints therebetween, the steps of applying lpaint to a at surfaced foundation web in Ian open lgrid Work pattern which will represent mortar joirtts in the nished covering, doctoring said paint while Wet to level and spread the same and reduce the thickness thereof in the mortar joint representing areas, with a portion of the paint being spread beyond the mortar joint representing areas, applying paint of a contrasting color in tile representation in sufficient thickness to lie above the mortar joint representing areas, said tile representing paint being applied in the open areas yof the Vfoundation not covered by the main mort-ar joint representing portions thereof and over the paint which has been spread beyond such areas in the leveling step, and thereafter bringing a peg surface from above into the paints throughout substantially their entire extent to level the same and cause the edges of the tile representing lportions to merge gradually and With rounded contours into the mortar joint representing portions to produce .a surface decoration in which the tile representing vareas lie in a plane above the plane of the mortar joint representing areas and the mortar joint representing areas are well defined.

6. The method in accordance with claim 1 in which the spreading action is effected by engaging the paint surface while wet with an oscillating and reciprocating surface pressed firmly into engagement with the wet paint.

7. In a method of decorating at surfaced coverings with a flat block printing machine, the steps of intermittently moving a web of fiat surfaced foundation material sequentially into a plurality of operating stations, applying a thin coat of paint to substantially the entire surface of the foundation at one station, printing a mortar joint representing paint in an `open grid work pattern upon the foundation web at another station, continuously engaging the surface of said foundation with the applied material thereon at still another station to level the mortar joint paint and reduce the thickness thereof, :and thereafter printing upon s-aid foundation web tile representing paint in the open areas of the mortar joint grid Work to produce a surface decoration in which the tile representing portions lie in a plane above the plane of the mortar joint representing portions.

8. In :a method of decorating flat surfaced coverings with a flat block printing machine, the steps of intermittently moving a web of nat surfaced foundation material sequentially into a plurality of operating stations, printing :a mortar joint representing paint in an open grid work pattern upon the lfoundation Web at one station, continuously engaging the surface of said foundation with the applied paint thereon at another station with a spreading surface While effecting relative movement in a direction parallel to the plane of the surface of the paint layer between said spreading surface and said paint layer to level the said paint layer and reduce the thickness thereof in the mortar joint representing areas, With a portion of the paint being spread beyond the mortar joint representing areas, and thereafter at .another station printing tile representing `paint upon said foundation in the open areas of the mortar joint representing grid Work and over the paint which has been spread beyond the mortar joint representing grid Work to produce a surface decoration in which the tile representing areas lie in -a plane above the plane of fthe mortar joint representing areas andthe mortar joint representing areas are Well defined.

9. In a method of ldecorating flat surfaced coverings with a fiat block printing machine, the steps of intermittently moving a web of flat surfaced foundation material sequentially into a plurality of operating stations, applying a thin coating of paint to substantially .the entire surface of the foundation, printing mortar joint representing paint in an open grid work pattern upon the foundation web, printing additional paint on the foundation in the joint representing areas which lie transversely of the length of the foundation, engaging said applied printing paints while still Wet with a spreading surface While effecting relative movement between the mortar joint representing paint layer and the spreading surface in -a direction parallel to the plane of the surface of the paint layer to spread and level the same and to reduce the thickness thereof in the mortar joint representing areas, with a yportion of the paint being :spread beyond the mortar joint representing areas, printing a narrow band of paint which outlines the tile representing areas and partially, at least, covers the paint which has been spread over such areas in the leveling step, applying additional outlining paint 4along those portions of the outline which extend transversely of :the web, printing upon said foundation web tile representing paint in the open areas of the mortar joint grid work and over the paint which has been spread beyond the grid work in the leveling step, overprinting said tile representing areas to apply additional paint thereto to cause the same to lie substantially above the mortar joint representing areas, and thereafter bringing a discontinuous surface from above into the paints in the tile representing areas throughout sub- .stantially their entire extent to level the same and FRANK J. SCHWARZ.

REFERENCES CITED The following references are of record in the le of this patent:

Number UNITED STATES PATENTS Name Date Nele Dec. 23, 1913 Prentis Jan. `13, 1931 Campbell Mar. 15, 1932 McCarthy Aug. 23, 1932 Marsh Nov. 22, 1938 Feder Feb. 16, .1943 

